Modular sports helmet

ABSTRACT

The present disclosure provides a modular helmet comprising a shell, an energy-absorbing layer, and at least one energy-absorbing panel or other modular element, which is removably attached to the helmet. For example, in accordance with an exemplary embodiment of the present disclosure, an improved football helmet comprises an outer shell with six apertures, an inner, energy-absorbing layer, a face mask, and six modular panels, each of which sits inside an aperture and is releasably attached to the outer shell.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a non-provisional of U.S. Provisional patent application Ser. No. 61/520,702 entitled “Modular Sports Helmet,” filed on Jun. 15, 2011, which is incorporated herein by reference.

FIELD OF INVENTION

This invention relates generally to a high-performance helmet incorporating a modular design to potentially achieve improvements in energy absorption and cost efficiencies. The characteristics of the disclosure may be particularly useful in high-impact sports such as football, lacrosse, hockey, baseball, softball, cycling, skating, skiing, polo, and the like.

BACKGROUND OF THE INVENTION

Many current helmet designs are essentially plastic, formed shells with some variation of energy-absorbing material, such as foams, air pads, or a combination of both, placed inside.

To optimize performance, many helmet designs attempt to balance competing functional features against an overall challenge of cost containment. In this regard, attempts are made to design helmets that not only to sustain the required impacts of their specific sport, but to provide adequate ventilation, to be capable of periodic repainting or refinishing, and frequently, to accommodate or support a separate face mask. Attempts to incorporate other criteria such as weight, stand-off distance from the user's head contours (“helmet profile”), and overall comfort have been made as well. However, such attempts are generally lacking to various degrees.

Moreover, many helmet designs are a single element design. The helmet may be capable of being refinished, but often, if a key element of the helmet is not functional, it should be replaced in whole. Replacement may be necessary due to damage, to old age, or to having been refinished too many times.

Known helmet designs can often be described as having two-stage energy absorption. In this respect, a hard, outer shell dissipates some of the impact load (“Stage 1”) and the materials inside the helmet further dissipate impact loads (“Stage 2”).

Due to the needs of creating a shell that is tough, durable, long-lasting, well-ventilated, low profile, lightweight, and capable of handling multiple impacts, of being refinished, and of functioning in high and low temperatures, many helmets are constructed with polycarbonate or ABS plastic molded shells that are thick and rigid.

These thick, rigid shells do not dissipate much energy during an impact, and as such, transfer much of it to the absorption materials inside the helmet. Therefore, Stage 1 of the energy absorption mechanism is largely ineffective, and the bulk of energy absorption is accomplished by Stage 2 design elements, namely the foams and air pads inside the hard shell.

Thus, technology that incorporates more energy absorption strategies is desirable because it can potentially decrease the incidence of athlete injury caused by traumatic head injuries, concussions, or repetitive head trauma. Additionally, technology that can realize different properties of different materials is desirable. Further, technology that allows partial replacement of helmet components is desirable because it may decrease the cost of helmet refurbishment and replacement.

SUMMARY OF THE INVENTION

While the ways in which the present disclosure addresses the disadvantages of the prior art will be discussed in greater detail below, in general, the present disclosure provides a modular helmet comprising a shell, an energy-absorbing layer, and at least one energy-absorbing panel, or other modular element, which is removably attached to the helmet.

For example, in accordance with the present disclosure, one or more panels, or the mechanism attaching the panels to the helmet, may provide additional stages of impact energy absorption and may be adapted to optimize performance for a specific sport or function by varying characteristics such as size, location, weight, material, method of attachment, and the like.

For example, in accordance with an exemplary embodiment of the present disclosure, an improved football helmet comprises an outer shell with six apertures, an inner, energy-absorbing layer, a face mask, and six modular panels, each of which sits inside an aperture and is releasably attached to the outer shell.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 a is a side view of a modular football helmet in accordance with an exemplary embodiment of the present disclosure.

FIG. 1 b is a perspective view of a modular football helmet in accordance with an exemplary embodiment of the present disclosure and illustrating the removable panels when released from the apertures.

FIG. 2 is a close-up cross-sectional view of a helmet with a depression and aperture, and a modular panel attached to the helmet in accordance with an embodiment of the present disclosure.

FIG. 3 is a cross-sectional view of a helmet with a depression, a modular panel, and an attachment mechanism, in accordance with an embodiment of the present disclosure.

FIG. 4 is a close-up cross-sectional view of a helmet shell with an aperture, a modular panel, and an attachment mechanism located on the perimeter edge of the panel and aperture in accordance with an embodiment of the present disclosure.

FIG. 5 is a close-up cross-sectional view of a helmet shell with an aperture and a depression, a modular panel, and an attachment mechanism located in the depression in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION

The following description is of an exemplary embodiment of the invention only, and is not intended to limit the scope, applicability, or configuration of the disclosure in any way. Rather, the following description is intended to provide a convenient illustration for implementing various embodiments of the disclosure. As will become apparent, various changes may be made in the function and arrangement of the elements described in these embodiments without departing from the scope of the disclosure as set forth in the claims.

For example, in the context of the present disclosure, the apparatus hereof finds particular use in connection with sports helmets such as football helmets, baseball helmets, hockey helmets, and the like. Additionally, the specific characteristics of each embodiment of the present disclosure are adapted to be optimized for performance in a particular sport. However, generally speaking, numerous applications of the present disclosure may be realized.

For example, although sports helmets are primarily used in conjunction with participation in an athletic activity, their general purpose is to protect the user's head from impact trauma. Accordingly, as used herein, the term “helmet” means any head-protective apparatus which at least partially surrounds the user's head. Briefly, other protective gear, such as elbow pads, knee pads, shin guards, and the like, may likewise benefit from the present disclosure, and use of the term “helmet” is not intended to limit the scope, applicability, or configuration of the disclosure in any way.

Likewise, numerous materials may be used to achieve each element of the apparatus disclosed herein. Generally speaking, elements of the disclosure may be made of various materials and composites, including polycarbonate plastic, ABS plastic, carbon fiber, metals, ceramics, polystyrene foam, vinyl nitrile foam, and thermoplastic urethane foam. That being said, although an exhaustive list of materials is not included herein, one skilled in the relevant art will appreciate that various conventional plastics and energy-absorbing materials may be used, all of which fall within the scope of the present disclosure.

Additionally, various materials may be combined to obtain the most attractive characteristics of existing (or as yet unknown) plastics, energy-absorbing materials, and composite materials, and may be incorporated into the helmet elements disclosed herein, whose combined performance characteristics may potentially increase impact energy absorption or cost efficiency.

As noted above, in conventional sports helmets, impact energy is dissipated in two stages, as accomplished by a hard, outer shell and an inner, energy-absorbing layer. In accordance with the present disclosure, further stages of impact energy absorption can be achieved through incorporation of modular design elements.

For example, a helmet may be improved with the addition of modular elements, such as panels, face masks, or the like, releasably attached to a shell, which surrounds a conventional, energy-absorbing layer. The modular elements can provide further stages of energy absorption by intentional deformation or release, thereby potentially decreasing the incidence of injury. Additionally, modular elements may be optionally removed and replaced after severe impacts, permanent deformation, ordinary wear and tear, or for any other reason. Modular design may improve cost efficiencies by decreasing the cost of helmet refurbishment and the frequency of helmet replacement.

Additionally, the mechanism attaching modular elements to the helmet may itself provide further stages of impact energy absorption. High-strain, rate-sensitive materials may help “tune” the level of energy (e.g., increase or decrease the amount of energy) required to remove a modular element. As such, the attachment mechanism may be made of various materials to meet the particular requirements of a specific sport, as determined by the types of impact the helmet is likely to receive. For example, a rigid impact panel that is separated from a rigid outer shell by an attachment mechanism made of a high-strain, moderate stiffness material may provide improved energy absorption for high load, short duration impacts.

For example, a baseball batter's helmet may have panels that permanently deform, thereby converting impact energy to strain energy, upon severe impact such as that caused by a fastball pitch. Deformed panels may be removed from the helmet and replaced. Alternatively, energy from a fastball pitch may be dissipated when the ball strikes a rigid panel, and an attachment mechanism made of moderate stiffness material designedly releases the panel from the helmet.

The above being noted, in accordance with an embodiment of the present disclosure, a helmet comprises a shell, an energy-absorbing layer, and at least one energy-absorbing panel, or other modular element, which is removably attached to the helmet. Briefly, these features of the present disclosure are provided in order that the detailed description herein will be better understood and appreciated; however, the present disclosure can also comprise additional features, which will be subsequently described herein.

For example, with reference to FIGS. 1 a and 1 b, a helmet 100 comprises a shell 101, which may be adapted to absorb impact energy. The shell 101 at least partially surrounds the user's head and provides the structural base of the helmet 100. The shell 101 may be hard and rigid, and its outer surface may be adapted to be painted, resurfaced, or refinished, potentially to accommodate graphic elements.

In various embodiments, the shell 101 may be made with materials such as ABS plastic, polycarbonate plastic, or the like. However, the shell 101 may be made of any number of plastics, energy-absorbing materials, or composite materials. Further, the shell's physical characteristics, such as flexibility, hardness, weight, and shape, may be varied in any way necessary to accomplish the desired performance characteristics while still falling within the scope of the present disclosure.

In an exemplary embodiment of the present disclosure, and with reference to FIGS. 1 a and 1 b, the shell 101 is shaped like a conventional football helmet and is located on the exterior of the helmet 100, contiguous with an inner, energy-absorbing layer 104. However, the shell 101 may be shaped to accommodate the needs of any particular sport, or more generally, in any way that at least partially surrounds the user's head. Further, the shell 101 need not constitute the outermost layer of the helmet 100, but may be located anywhere to accomplish energy absorption.

A layer 104 may be adapted to further absorb energy. The layer 104 may be more energy-absorbent than the shell 101, and may be comprised of foam lining, foam pads, air pads, or any combination thereof. That being said, the layer 104 may be comprised of any apparatus that effectively absorbs impact energy and generally cushions the user's head.

Foam lining and foam pads generally may be made of polystyrene foam, vinyl nitrile foam, or thermoplastic urethane foam. Air pads generally may comprise bladders adapted to be filled with air and may be made of vinyl or a similarly flexible plastic material. That being said, the layer 104 may be made of any material that is sufficiently adapted to absorb impact energy.

The layer 104 may be located inside the shell 101, and may be contiguous with the inner surface of the shell 101. In embodiments comprising foam pads or air pads, the pads may be placed strategically inside the helmet 100 to meet the specific requirements of a particular sport, or to optimize characteristics such as energy absorption, user comfort, and helmet profile. That being said, the layer 104 need not be contiguous with the shell 101, and other elements may be interposed between the shell 101 and the layer 104.

In accordance with the present disclosure, still further energy absorption may be accomplished by modular design elements.

For example, one or more panels may be releasably attached to the helmet, potentially providing more effective energy absorption than the hard, outer shell of conventional helmets. Accordingly, improved energy absorption may increase the helmet's ability to prevent injury. Further, the optional ability to remove and replace panels or other modular elements may improve cost efficiencies by decreasing the cost of helmet refurbishment and the frequency of helmet replacement.

Panels may be intentionally frangible as a means of achieving improved energy absorption and of providing a visual indicator of impact. Frangible panels may be designed to permanently deform upon severe impact or to temporarily deform. Alternatively or in conjunction with deformation, the panels may achieve improved energy absorption by intentionally detaching from the helmet upon impact, thereby dissipating impact energy as strain energy.

That being said, although an exhaustive list of means for absorbing or dissipating energy is not included herein, one skilled in the relevant art will appreciate that various means may be used, all of which fall within the scope of the present disclosure.

Panels may be made of various materials or composites, including polycarbonate plastic, ABS plastic, carbon fiber, metals, ceramics, and the like. Different properties and their concomitant benefits may be realized through use of materials that vary in stiffness, strength, weight, flexibility, hardness, energy-absorption ability, cost, or any other characteristic. That being said, although an exhaustive list of materials is not included herein, one skilled in the relevant art will appreciate that various conventional plastics and energy-absorbing materials may be used, all of which fall within the scope of the present disclosure.

Panels may be strategically located on the helmet to increase energy absorption. Panels may be located on the exterior of the shell, may be interposed between the shell and the layer, or may be located on the inner surface of the layer. Additionally, panels may be located strategically to meet the specific requirements of a particular sport.

For example, in the present exemplary embodiment, a football helmet, panels 103 may be located on portions of the helmet 100, such as the anterior, posterior, and lateral faces, which are likely to receive impacts as a result of tackling. In one alternate embodiment, a baseball batter's helmet, panels may be located on portions of the helmet, such as the posterior and lateral faces, which are likely to receive impacts as a result of pitching. That being said, those skilled in the relevant art will appreciated that the panels' location may vary depending on the particular requirements of each helmet, and the embodiments described herein is not intended to limit the scope of the present disclosure.

Additionally, the shell may comprise depressions or apertures, and panels may be located therein. Apertures and depressions may decrease the helmet's weight, may optimize performance, may be an element of aesthetic design, may accommodate modular elements of the helmet, or may be adapted for any other function.

For example, a shell may be shaped like a conventional bicycle helmet, comprising multiple apertures of varied size and shape, designed to decrease helmet weight and increase aerodynamic performance. Alternatively, a shell may be comprised of multiple depressions to decrease helmet profile, thereby increasing aesthetic quality and self-recognition, as measured by the user's ability to pass a mirror test. In the exemplary embodiment of the present disclosure, the shell 101 comprises six apertures 105, each adapted to releasably hold an energy-absorbing panel 103.

With reference now to FIG. 4, a panel 103 may be located in an aperture 105 of the shell 101. In another embodiment and with reference to FIG. 3, a panel 103 may be located in a depression 108 of the shell 101. In yet another embodiment and with reference to FIG. 5, a panel 103 may be located in both a depression 108 and an aperture 105 of the shell 101, such that the aperture 105 is formed at the bottom of the depression 108 and is adapted to releasably hold the panel 103 in place.

That being said, a panel need not be located in a depression or aperture, and the size, shape, and number of apertures or depressions may vary depending on the particular helmet characteristics desired, or the specific requirements of a particular sport. Additionally, and in accordance with the present disclosure, the shell may or may not comprise apertures, and it may or may not comprise depressions.

Further, a panel which is located in a depression or aperture may or may not have the same three-dimensional profile as the depression or aperture. However, panels sharing the three-dimensional profile of a depression can potentially decrease the helmet profile and create a continuous outer surface of the helmet that is aesthetically pleasing.

With reference to FIG. 2, a panel 103 may be located in a depression 108 formed in the shell 101 partially surrounding the user's head 107, such that the distance from the outer surface of the panel 103 to the inner surface of the attachment mechanism 109 is approximately equivalent to the depth of the depression 108. In another embodiment and with reference to FIG. 4, a panel 103 that sits in an aperture 105 may share substantially the same surface profile as the aperture 105 in which it fits, so as to minimize helmet profile and create a continuous outer surface of the helmet that is aesthetically pleasing.

That being said, the depth, orientation, and profile of a panel located in either a depression or an aperture may vary. In the present exemplary embodiment, a helmet 100 comprises panels 103, which are located in apertures 105 of approximately equivalent orientation and profile. However, apertures, depressions, and panels may take any number of sizes, shapes, and configurations, and the exemplary embodiment described herein is not intended to limit the scope of the present disclosure. As will be appreciated, the specific requirements of a particular sport may require panels of varying depth, profile, and orientation for optimal energy absorption.

Panels themselves may additionally comprise one or more vents of varying size and shape. Panel vents may function to increase ventilation and airflow, thereby improving user comfort. Panel vents may also increase energy absorption, increase aerodynamic performance, increase aesthetic appeal, or decrease weight, among other things. In the present exemplary embodiment, a helmet 100 comprises panels 103 with panel vents 106 which are generally oval in shape and are orientated parallel to one another. That being said, panel vents may take any number of sizes, shapes, and orientations, and the exemplary embodiment described herein is not intended to limit the scope of the present disclosure.

Panels may be releasably attached to the helmet to accomplish any of several functions. For example, releasable attachment improve energy absorption; it may allow panel replacement in the event of deformation after impact; it may allow panel reattachment in the event of intentional detachment after impact; and it may allow panel replacement in the event of helmet damage, regular wear and tear, or for any other reason. Accordingly, improved energy absorption may increase the helmet's ability to prevent injury. Further, the optional ability to remove and replace panels may improve cost efficiencies by decreasing the cost of helmet refurbishment and the frequency of helmet replacement

With reference to FIG. 2, a panel 103 may be releasably attached to the shell 101 by a panel attachment mechanism 109. The attachment mechanism 109 may be made of various high strain, rate-sensitive materials which increase energy absorption through planned failure at specific loads, as determined by the types of impact the helmet is likely to receive.

The panel attachment mechanism 109 can be adapted to hold a panel 103 securely in place on the shell 101, but to intentionally release the panel 103 with application of sufficient force, and thereafter, to optionally receive a panel, again holding it in place. Further, the panel attachment mechanism 109 may be adapted to join a panel with the shell interior, the shell exterior 101, a shell depression 108, a shell aperture 105, the layer 104, or any other locus on the helmet.

Additionally, the panel attachment mechanism may comprise channel supports adapted to attach a panel to the helmet. The channel support members may be semi-rigid and adapted to interlock with one another upon application of sufficient force. The channel support members are further adapted to release upon subsequent applications of sufficient impact force.

In one embodiment and with reference to FIG. 3, two channel support members 110, 111 can be respectively located in a depression 108 on the exterior surface of the shell 101 and on the proximal surface of a panel 103. In another embodiment and with reference to FIG. 4, channel supports 112 may be located on the perimeter edges of a panel 103 and a shell aperture 105, respectively.

In other embodiments, the panel attachment mechanism may include a slide-locking mechanism, a hook and slot mechanism, a magnetic mechanism, an adhesive, or the like. It will be appreciated that, although an exhaustive list is not included herein, one skilled in the relevant art will appreciate that various attachment mechanisms may be used, all of which fall within the scope of the present disclosure.

Still further energy absorption may be achieved by a face mask, releasably attached to the helmet. Accordingly, improved energy absorption may increase the helmet's ability to prevent injury. Further, the optional ability to remove and replace the face mask may improve cost efficiencies by decreasing the cost of helmet refurbishment and the frequency of helmet replacement.

The face mask may be intentionally frangible as a means of achieving improved energy absorption. A frangible face mask may be designed to permanently deform upon severe impact or to temporarily deform. Alternatively or in conjunction with deformation, the face mask may achieve improved energy absorption by intentionally detaching from the helmet upon impact, thereby dissipating impact three as kinetic energy. That being said, although an exhaustive list of means for absorbing or dissipating energy is not included herein, one skilled in the relevant art will appreciate that various means may be used, all of which fall within the scope of the present disclosure.

As with other components described herein, facemask may be made of various materials or composites, including polycarbonate plastic, ABS plastic, carbon fiber, metals, ceramics, and the like. The specific requirements of the facemask can determine the type of material used, and the material used may vary in weight, flexibility, hardness, energy-absorption ability, cost, or any other characteristic. That being said, although an exhaustive list of materials is not included herein, one skilled in the relevant art will appreciate that various conventional plastics and energy-absorbing materials may be used, all of which fall within the scope of the present disclosure.

In the exemplary embodiment of the present disclosure, a face mask 102 may be adapted to be releasably attached to the helmet 100 by a helmet attachment mechanism similar to the panel attachment mechanism described herein. The face mask 102 may be configured as a conventional football helmet face mask and may be releasably attached to the exterior surface of the shell 101 along the perimeter of the shell's anterior edge. Alternatively, the face mask 102 may be attached to the shell 101, to the layer 104, to a panel 103, or to any other locus on the helmet 100. That being said, the location of the face mask attachment mechanism, as well as the configuration and orientation of the face mask, may be adapted to meet the requirements of any sport.

Additionally, the attachment mechanism described herein may be adapted to attach other modular helmet elements, as required by any particular sport. Other modular helmet elements may include a chin strap, unitary face shield, visor, strap and ratchet apparatus, or the like.

Finally, in the foregoing specification, the disclosure has been described with reference to specific embodiments. However, one skilled in the art appreciates that various modifications and changes can be made without departing from the scope of the present disclosure as set forth in the claims below. Accordingly, the specification is to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of the present disclosure.

Likewise, benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature or element of any or all of the claims. As used herein, the terms “comprises” and “comprising,” or any variations thereof, are intended to constitute a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements, but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. 

1. A helmet for as user's head, comprising: a shell that at least partially surrounds the user's head, an energy-absorbing layer, and at least one energy-absorbing panel, wherein the panel is removably attached to the helmet.
 2. A helmet according to claim 1, further comprising a panel attachment mechanism.
 3. A helmet according to claim 2, wherein the panel attachment mechanism comprises semi-rigid channel supports.
 4. A helmet according to claim 3, wherein the channel supports are located on the shell.
 5. A helmet according to claim 1, wherein the panel is frangible.
 6. A helmet according to claim 1, further comprising a face mask.
 7. A helmet according to claim 6, wherein the face mask is frangible.
 8. A helmet according to claim 7, wherein the face mask is removably attached to the helmet.
 9. A helmet according to claim 1, further comprising a chin strap.
 10. A helmet according to claim 1, wherein the shell has at least one aperture.
 11. A helmet according to claim 10, wherein the aperture is adapted to receive and releasably hold the panel in the aperture, and wherein the aperture has substantially the same profile as the panel.
 12. A helmet according to claim 1, wherein the panel has at least one aperture.
 13. A helmet according to claim 1, wherein the shell has at least one depression adapted to receive and releasably hold the panel in the depression.
 14. A helmet according to claim 13, wherein the depression has substantially the same profile as the panel.
 15. A helmet according to claim 1, wherein the layer comprises foam, and wherein the foam is contiguous with the inner surface of the shell.
 16. A helmet according to claim 1, wherein the layer comprises air pads, and wherein the air pads are contiguous with the inner surface of the shell.
 17. A football helmet for a user's head, comprising a shell that at least partially surrounds the user's head, an energy-absorbing layer contiguous with the inner surface of the shell, a face mask attached to the helmet, and and at least six energy-absorbing, removable panels.
 18. A football helmet according to claim 17, wherein one panel is located on the anterior face of the shell, one panel is located on the posterior face of the shell, and two panels are located on each lateral face of the shell, wherein one lateral panel is superficial to the other on each lateral face.
 19. A helmet for a user's head, comprising a shell that at least partially surrounds the user's head, an energy-absorbing layer, and a face mask, wherein the face mask is frangible and removably attached to the helmet. 